Toyota Corolla (E120) 2002–2008 Repair Manual / Automatic transmission / trans / Manual transaxle assy / Replacement

Toyota Corolla (E120): Replacement

Hint

: components:

1. Place front wheels facing straight ahead

2. Remove front wheels

3. Remove engine under cover lh

4. Remove engine under cover rh

5. Remove exhaust pipe

6. Drain transaxle oil

7. Remove hood sub–assy

8. Remove cylinder head cover no.2

9. Remove air cleaner assy

10. Remove battery clamp sub–assy

11. Remove battery

12. Remove battery tray

13. Remove battery carrier

1. Remove the 4 bolts and battery carrier.

14. Remove cruise control actuator assy (w/ cruise control)

15. Disconnect wire harness

1. Disconnect the wire harness clamp.
2.  remove the 2 bolts and disconnect the 2 wire harness brackets.

3. Remove the 2 bolts and 2 ground cables.

16. Disconnect connector

1. Disconnect the back–up lamp switch connector.

2. W/o abs: disconnect the speed sensor connector.

17. Separate clutch release cylinder assy

1. Remove the 5 bolts, separate the release cylinder assy with clutch piping from the transaxle.

18. Separate floor shift cable transmission control shift

1. Remove the clip, washer and disconnect the shift cable from the transaxle.
2.  remove the clip and disconnect the shift cable from the bracket.

19. Separate floor shift cable transmission control select

1. Remove the clip, washer and disconnect the select cable from the transaxle.
2.  remove the clip and disconnect the select cable from the bracket.

20. Remove starter assy

1. Remove the nut and disconnect the starter wire.
2.  disconnect the connector.
3.  remove the 2 bolts and starter assy.

21. Separate steering intermediate shaft

22. Remove front drive shaft assy lh

 sst 09520–01010, 09520–24010 (09520–32040)

23. Remove front drive shaft assy rh

Hi

nt: remove the rh side by the same procedures as lh side. Sst 09520–01010, 09520–24010 (09520–32040)

24. Separate return tube sub–assy

 sst 09023–12700

25. Separate pressure feed tube assy

26. Suspend engine assy

1. Remove the 2 pcv hoses.
2.  install the 2 hangers in the correct direction.

   Parts no.:
   Engine hanger: 12281–22021 no.1 Engine hanger: 12281–15040 bolt: 91512–b1016
   torque: 38 nvm (387 Kgf·cm, 28 ft·lbf)

3.  attach the engine chain hoist to the hangers.

Caution

: do not attempt to hang the engine by hooking the chain to any other part.

27. Remove front suspension crossmember sub–assy

28. Support manual transaxle assy

1.  support the transaxle with a transmission jack.

29. Remove transverse engine engine mounting insulator

1. Remove the 5 bolts, nut and engine mounting insulator lh from the body.

30. Remove transverse engine engine mounting bracket

1. Remove the 3 bolts and engine mounting bracket lh from the transaxle.

31. Remove manual transaxle assy

1. Remove the 6 bolts and transaxle from the engine.

32. Remove transverse engine engine mounting bracket

1. Remove the bolt, nut and engine mounting insulator fr from the engine mounting bracket fr.
2.  remove the 2 bolts and engine mounting bracket fr from the transaxle.

33. Remove transverse engine engine mounting bracket

1. Remove the bolt and engine mounting insulator rr from the engine mounting bracket rr.
2.  remove the 3 bolts and engine mounting bracket rr from the transaxle.

34. Install transverse engine engine mounting bracket

1. Install the engine mounting bracket rr and 3 bolts to the transaxle.

   Torque: 64 nvm (653 Kgf·cm, 47 ft·lbf)

2.  install the engine mounting insulator rr and bolt to the engine mounting bracket rr.

   Torque: 87 nvm (888 Kgf·cm, 64 ft·lbf)

35. Install transverse engine engine mounting bracket

1. Install the engine mounting bracket fr and 2 bolts to the transaxle.

   Torque: 64 nvm (653 Kgf·cm, 47 ft·lbf)

2.  install the engine mounting insulator fr, bolt and nut to the engine mounting bracket fr.

   Torque: 52 nvm (530 Kgf·cm, 38 ft·lbf)

36. Install manual transaxle assy

1. Align the input shaft with the clutch disc and install the transaxle to the engine.
2.  install the 6 bolts.

   Torque:
   bolt a: 64 nvm (650 Kgf·cm, 47 ft·lbf) bolt b: 47 nvm (480 Kgf·cm, 35 ft·lbf) bolt c: 23 nvm (230 Kgf·cm, 17 ft·lbf)

37. Install transverse engine engine mounting bracket

1. Install the engine mounting bracket lh to the transaxle with the 3 bolts.

   Torque: 52 nvm (530 Kgf·cm, 38 ft·lbf)

38. Install transverse engine engine mounting insulator

1. Install the engine mounting insulator lh with the 5 bolts and nut.

   Torque:
   bolt a: 52 nvm (530 Kgf·cm, 38 ft·lbf) bolt b: 80 nvm (816 Kgf·cm, 59 ft·lbf)

39. Install front suspension crossmember sub–assy 

sst 09670–00010

40. Connect steering intermediate shaft

41. Install column hole cover silencer sheet

42. Connect return tube sub–assy 

sst 09023–12700

43. Connect pressure feed tube assy 

sst 09023–12700

44. Install front drive shaft assy lh

45. Install front drive shaft assy rh

H

int

: install the rh side by the same procedures as lh side.

46. Install starter assy

1. Install the starter assy and 2 bolts to the transaxle.

   Torque: 37 nvm (378 Kgf·cm, 27 ft·lbf)

2.  connect the starter connector.
3.  install the wire and nut to starter assy.

   Torque: 9.8 Nvm (100 Kgf·cm, 87 in.Vlbf)

47. Connect floor shift cable transmission control shift

1. Connect the shift cable end, and install the washer and clip.

48. Connect floor shift cable transmission control select

1. Connect the select cable end, and install the washer and clip.

49. Connect clutch release cylinder assy

1. Install the release cylinder with the 5 bolts.

   Torque:
   bolt a: 25 nvm (250 Kgf·cm, 19 ft·lbf) bolt b: 12 nvm (120 Kgf·cm, 9 ft·lbf) bolt c: 5.0 Nvm (51 Kgf·cm, 44 in.Vlbf)

50. Connect connector

1. Connect the back–up lamp switch connector.

2. W/o abs: connect the speed sensor connector.

51. Connect wire harness

1. Install the 2 wire harness clamps to the transaxle with the 2 bolts.

   Torque:
   bolt a: 25.5 Nvm (260 Kgf·cm, 19 ft·lbf) bolt b: 12.8 Nvm (131 Kgf·cm, 9 ft·lbf)

1.  connect the wire harness clamp.

2. Install the 2 bolts and 2 ground cables.

   Torque: 13 nvm (133 Kgf·cm, 10 ft·lbf)

52. Install cruise control actuator assy (w/ cruise control)

53. Install battery carrier

1. Install the battery carrier and 4 bolts.

   Torque: 13 nvm (133 Kgf·cm, 10 ft·lbf)

54. Install battery tray

55. Install battery

56. Install battery clamp sub–assy

Torque:
bolt: 5.0 Nvm (51 Kgf·cm, 44 in.Vlbf) nut: 3.5 Nvm (36 Kgf·cm, 31 in.Vlbf)

57. Install air cleaner assy

torque: 7.0 Nvm (71 Kgf·cm, 62 in.Vlbf)

58. Install cylinder head cover no.2

Torque: 7.0 Nvm (71 Kgf·cm, 62 in.Vlbf)

59. Install hood sub–assy

torque: 13 nvm (133 Kgf·cm, 10 ft·lbf)

60. Inspect hood sub–assy

61. Adjust hood sub–assy

62. Add transaxle oil

63. Inspect transaxle oil

64. Bleed power steering fluid

65. Install front wheels

torque: 103 nvm (1,050 Kgf·cm, 76 ft·lbf)

66. Place front wheels facing straight ahead

67. Install exhaust pipe

68. Install engine under cover lh

69. Install engine under cover rh

70. Inspect front wheel alignment

71. Check abs speed sensor signal